MRP User Guide and Process Flow

Table of Contents
MATRAIL REQUIREMENT PLANNING ............................................................................................. 2

Detailed Process Flow-Manufactured items .................................................................................. 3

Details Process flow -Traded FG .................................................................................................... 3

Master Data- Item site Planning Maintenance ............................................................................... 4

Item site planning Rules – manufactured items ............................................................................. 5

Item Site Planning Rules – Traded FG Parts ................................................................................... 5

Source Network Maintenance ....................................................................................................... 7

BOM Exception Maintenance ........................................................................................................ 8

Alternate Structure Maintenance ................................................................................................. 8

Production Plan Upload ............................................................................................................... 9

Traded FG Upload ...................................................................................................................... 10

MRP RUN ................................................................................................................................... 11

MRP Reports – MRP Summary Inquiry ........................................................................................ 12

MRP Reports – MRP Summary Report ......................................................................................... 14

Planned Order Approval ............................................................................................................ 19

Requisition Maintenance ........................................................................................................... 22

Requisition Approval Maintenance ............................................................................................. 23

Builed PO from Requisition ........................................................................................................ 24

Requisition Browse .................................................................................................................... 26

Action Message Review .............................................................................................................. 27

Common Action Messages .......................................................................................................... 28

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 MRP User Guide and Process Flow

MATRAIL REQUIREMENT PLANNING

Material Requirement Planning: MRP balances supply and demand for purchased and
manufactured items. Given a set of demands or requirements, MRP automatically
calculates a time-phased schedule of planned supply orders or replenishments to satisfy
those demands.

It also generates action messages to alert you to any problems such as shortages and
late receipts.

• MRP looks at demand for finished items and uses product structure information
to calculate demand for component items.
• For each item, MRP looks at the:
o Ordering information
o Amount currently on hand.
o Lead times.

MRP then generates planned orders suggesting how many of each item to buy
or make and when to do so.

MRP's planning activity is performed by site.

• Each site's material plan is completely independent from inventory, demand, and
supply at other sites.
• To plan for multiple sites, you run MRP for each site separately.

Reliable MRP processing depends on correct:

• Inventory data.
• Product structures and formulas
• Manufacturing and purchasing lead times.

MRP attempts to balance supply and demand. It detects imbalances in the plan and
makes recommendations to restore the balance.

• It tries to drive inventory to zero, never planning more than it needs.

• It plans without respect to capacity.

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 MRP User Guide and Process Flow

Detailed Process Flow-Manufactured items

MRP To Be Process Flow – Manufactured Items
Astriks QAD – Manufacturing Site QAD Sourcing Site

Inter Site Requests Available for

18 Month Production
MRP based on Sourcing Grid
Plan Prepared in Astricks
(6 Month Week Wise, Upload Data into QAD
12 Month Monthwise) In Schedule Maintenance using Consolidated Requirement available to MRP across all Manuf Sites
Production Plan Upload
(New Custom Program)
Regenrative MRP Run

Data Extracted from

Astriks and plan
updated to Site Wise YES Select Alternate BOM
(4 Month Day Wie, 6 BOM Exception
Month Week Wise (Refer Appendix 2)
and 8 Month
MonthWise)
Check P/D Flag in Create Inter Site
Select Standard BOM Item Site Planning Request
NO from Item Site
Planning

Manual File Transfer Purchase Item

Data Uploaded to
Schedule Maintenance in Generate Planned
QAD Purchase Order By
Manual File Prepared
Site Wise in CSV Format Site
(Format Appendix 1)

Approve Planned
Regenrative MRP Run Purchase Order By
Site

RM Requirement Generated by MRP

Generate Purchase
Requisition
Check P/D Flag in
Sourcing Item
Item Site Planning

Create Inter Site Approve Purchase

Purchase Item Request Requisition

Generate Planned
Purchase Order By
Site Build Purchase Order
from Requisition

Approve Planned
Purchase Order By
Site

Generate Purchase
Requisition

Approve Purchase
Requisition
Phase

Build Purchase Order

from Requisition

Details Process flow -Traded FG

MRP To Be Process Flow – Traded FG SKUs
Astriks QAD – Depo Sites QAD Sourcing Site

Inter Site Requests Available for

18 Month Production
MRP based on Sourcing Grid
Plan Prepared in Astricks
(6 Month Week Wise, Upload Data into QAD
12 Month Monthwise) In Forecast Maintenance using Consolidated Requirement Available to MRP from across Depot Sites
Forecast Upload
(New Custom Program)
Regenrative MRP Run

Data Extracted from

Astriks and plan
updated to Site Wise
(4 Month Day Wie, 6 Regenrative MRP Run
Month Week Wise
and 8 Month
MonthWise) Check P/D Flag in Create Inter Site
FG Requirement Generated by MRP Item Site Planning Request

Manual File Transfer

Check P/D Flag in Purchase Item

Sourcing Item
Item Site Planning
Generate Planned
Purchase Order By
Manual File Prepared Create Inter Site
Site Wise in CSV Format Site
Purchase Item
Request
(Format Appendix 1)

Generate Planned Approve Planned

Purchase Order By Purchase Order By
Site Site

Approve Planned Generate Purchase

Purchase Order By Requisition
Site

Approve Purchase
Generate Purchase
Requisition
Requisition

Build Purchase Order

Approve Purchase
from Requisition
Requisition

Build Purchase Order

from Requisition
Phase

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 MRP User Guide and Process Flow

Master Data- Item site Planning Maintenance

For Items Purchased directly at the Manufacturing Site, the following Master Data needs
to be maintained:

• Item-Site Planning
o Order Policy: POQ
o Order Period: 7 Days to Start With
o P/M Flag: “P”
o Safety Stock, Supplier Lead Time, MOQ, Order Multiples
o Master Schedule = NO, Planned Orders = YES

For Item sourced from Warehouse, the following Master Data needs to be maintained:

• Item-Site Planning
o Order Policy: POQ
o Order Period: 1 Day
o P/M Flag: “D”
o Safety Stock
o Network Code = <Shipping Site> + “-” + <Receiving Site>

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 MRP User Guide and Process Flow

Item site planning Rules – manufactured items

For Items at Sourcing Site, the following Master Data needs to be maintained:

• Item-Site Planning
o Order Policy: POQ
o Order Period: 7 Days to Start With
o P/M Flag: “P”
o Safety Stock, Supplier Lead Time, MOQ, Order Multiples
o Master Schedule = NO, Planned Orders = YES

BOM Exceptions

• For Milk based Items, define the Alternate BOM to be used based on Site and
Period
• For Ice Cream Products, to avoid WIP planning, define the MRP BOM to be used.
If no record I found for SKU, system will pick the default BOM Code for that SKU.

Item Site Planning Rules – Traded FG Parts

For Items Purchased directly at the Depot Site (Jordan, Exports), the following Master
Data needs to be maintained:

• Item-Site Planning
o Order Policy: LFL
o P/M Flag: “P”
o Safety Stock, Supplier Lead Time, MOQ, Order Multiples
o Master Schedule = YES, Planned Orders = YES

For Item sourced from Warehouse, the following Master Data needs to be maintained:

• Item-Site Planning
o Order Policy: POQ
o Order Period: 1 Day
o P/M Flag: “D”
o Safety Stock
o Network Code = <Shipping Site> + “-” + <Receiving Site>

For Items at Sourcing Site, the following Master Data needs to be maintained:

• Item-Site Planning
o Order Policy: LFL
o P/M Flag: “P”
o Safety Stock, Supplier Lead Time, MOQ, Order Multiples
o Master Schedule = YES, Planned Orders = YES

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 MRP User Guide and Process Flow

Network Code Maintenance

• Sourcing Grid Definition is defined here.

• Network Code: <Shipping Site>+”-” +<Receiving Site>

• Description: Meaning Description of the Network Grid

• Planner: In case you have different planners for each grid, separate planners
could be defined. This is defaulted in certain reports and selection criteria.

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 MRP User Guide and Process Flow

Source Network Maintenance

• Sourcing Grid Definition Detail is defined here.

• Network Code: As created in the Network Code Maintenance

• Receiving Site: Site Receiving the Material

• Shipping Site: Site Shipping the Material

• Start: From when relation is applicable. This manages any changes to network
grid effective as of a date. The last record available for the Network Code will be
considered.

• Supply Percent: If one part in a site is supplied by multiple supply sites, then a %
of supply can be mentioned. In SADAFCO this is 100% for the supply site, as we
have a single source supply.

• Transportation Code: Used when Gate Pass or Inter site requests are created and
used from QAD. Currently in SADAFCO Gate Pass is manual, and hence this code
will be blank.

• Planner: In case you have different planners for each grid, separate planners
could be defined. This is defaulted in certain reports and selection criteria.

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 MRP User Guide and Process Flow

BOM Exception Maintenance

• Item: Select the Item Code for which Alternate BOM is to be Maintained

• Site: Production Plan Site Code

• Start Date: Start Date of the Alternate BOM Consideration

• End Date: End Date of the Alternate BOM Consideration

• Alternate BOM: Alternate BOM to be used.

Note: Only those Alternate BOMs are allowed which are defined in QAD 13.15 Alternate
Structure Maintenance

Alternate Structure Maintenance

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 MRP User Guide and Process Flow

• Item Number: Select the Item Code for which Alternate BOM is to be Maintained.

• BOM/Formula Code: Alternate BOM Code to be used.

• Remarks: Comments if any.

Note: For each Item which has an alternate BOM need to be maintain here in Alternate
Structure Maintenance as shown in below screenshot.

Production Plan Upload

Production Plan is downloaded from Astricks.

The format of the download file is shared. The columns are:

• Site: Should be a valid site in QAD

• Part: Should be a Valid Part in QAD, should have a routing and BOM. In case BOM
exception is defined, the Alternate BOM should be defined.
• Date: Format should be DD-MM-YY. E.g. 10-02-24 for 10th Feb 2024
• Quantity: Quantity without any format.
• There should be no header row in the file and should be a csv format.

Production Plan is CIM Loaded into 18.22.2.1. Before loading fresh plan, the earlier
plans are initialized.

Data Loaded in Production Plan can be verified using MRP Schedule Browse (18.2.99)

We have currently setup a auto batch for the same. If it is required to upload rather than
the batch setup time then we have to follow the process described. Apart from that need
to put file in specified given folder batch will auto pick the file and load the same.

Program Name: xxprplup.p

Run Mode: Character Client by IT Team for first 4 Runs

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 MRP User Guide and Process Flow

Traded FG Upload
Traded FG Forecast is downloaded from Astricks.

The format of the download file is attached for reference. The columns are:

o Site: Should be a valid site in QAD

o Part: Should be a Valid Part in QAD, should have a routing and BOM. In case BOM
exception is defined, the Alternate BOM should be defined.
o Date: Format should be DD-MM-YY. E.g. 10-02-24 for 10th Feb 2024
o Quantity: Quantity without any format.
o There should be no header row in the file and should be a csv format.

Traded FG Forecast is CIM Loaded into Forecast Maintenance 22.1. Before loading fresh
forecast, the earlier forecasts are initialized except for Site 18. This is kept ensuring no
other current reports are affected.

Data Loaded in Forecast Maintenance can be verified using Forecast Report (22.4)

Program Name: xxfcplup.p

To upload forecast we have scheduled a auto batch. So need to put a file in specified
folder. Auto batch will pick the file and load the data. Apart from that If there is any need
to load the same then we can load as per described process.

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 MRP User Guide and Process Flow

MRP RUN
MRP has to be run for Each Manufacturing / Depot and Sourcing Site one after the other.

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 MRP User Guide and Process Flow

MRP Reports – MRP Summary Inquiry

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 MRP User Guide and Process Flow

For the MRP report go to MRP Summary inquiry menu. This summery inquiry report
can be getting data month wise, week wise summery report.

Below are the available filters.

• Select the item.

• Select the site.
• Select the start date.
• Select the End date.
• Select the column type.
• Select the per column “1.”
• After all data fill up, run the report.
• It will show the category wise report like gross requirements, schedule receipt,
project QDH, plan order due and plan order release.

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 MRP User Guide and Process Flow

MRP Reports – MRP Summary Report

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 MRP User Guide and Process Flow

For this report go to the MRP Summary report menu. Users can search using the
available filters below.

• Select the item number.

• Select the to item code.
• Select the site.
• Enable the flag of the “Use Cost Plans.”
• Enable the flag of the “Include Base Process Orders.”
• Select the start date.
• Select the end date.
• Click on the NEXT button two times.

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 MRP User Guide and Process Flow

MRP Reports – MRP Detail Inquiry

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 MRP User Guide and Process Flow

For MRP details Inquiry go to MRP details Inquiry menu. Users can search using the
available filters below.

• Select the item number.

• Select the site.
• Select the start date.
• After entering the start date click on the “next” button, it shows the item and
description.
• Select the output.
• Click on the next button it shows the MRP Details Inquiry.

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 MRP User Guide and Process Flow

MRP Reports – Past Due Receipts

Past Due Receipts Inquiry (23.19) shows you past due receipts. Because the projected
quantity on hand value uses released order due dates for supply, orders that become
past due are a real problem. It is imperative that past due orders be rescheduled with a
due date in the future for the projected quantity on hand value to be meaningful. MRP
has no logic to deal with past due orders, they are lumped into the first column of the
summary inquiry screen as past due.

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 MRP User Guide and Process Flow

Planned Order Approval

Planned Purchase Order Approval (23.11) approves the MRP plan, generating purchase
requisitions for the amount of each planned order. From here, the requisitions are ready
to print. This action moves the purchase orders out of the MRP module and into the
purchasing module. On the first screen, select the planned orders to approve, usually for
a range of items and release dates. To approve the entire group, set Default Approve to
Yes.

This screen displays outstanding MRP-generated purchase requisitions and enables you
to approve them. Enter the line number in the indicated field to access the appropriate
data.

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 MRP User Guide and Process Flow

After the Planned purchase order approve the MRP plan, it’s generating purchase order
requisition for each plan order. Below the attached screenshot of the planned purchase
order approval screen, it shows the line wise data of the planned order. If you want the
approve the order you can enable the flag of the “Appr.” Click on the “Next “button.

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 MRP User Guide and Process Flow

After the Click on next button it generates the Request number “RQ54”.

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 MRP User Guide and Process Flow

Requisition Maintenance
Using this menu create or modify purchase requisitions. For modify, in the "Req Number"
field, type the request number. All of the information will appear in this menu once you enter
the requisition number. And to create requisition number leave it blank and click on next
button rest of details would be same. Here you can update the qty if required. Also it will
route for approvals as per master setup matrix. If no approval is required then it will be
default approve.

Note: Supplier is not mandatory field.

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 MRP User Guide and Process Flow

Requisition Approval Maintenance

Requisition approval maintenance screen use to approve the requisition. Requisition
process according to the roles and levels of the employees who are authorized person to
approve requisitions.

Follow the below mention points.

• Select the View Queue/Dispositioned

• Select the user ID.
• Select the Request number.
• To view, enable the flag of the “View Requisition.”
• For modify, enable the flag of the “Modify Requisition.”
• Enable the Flag of the “Maintain Approval Comment.”
• Select the Action which action authorized want to take against the requisition.
➢ 1: Approve the requisition
➢ 2: Deny the requisition
➢ 3: Reverse an earlier approval or Reject

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 MRP User Guide and Process Flow

Builed PO from Requisition

Build Po from requisition menu use to create a purchase order which existing from
approved requisitions. This menu only used approved requisitions are available for
selection during PO build.

Follow the below mention points for the build PO.

• Select the Requisition number.

• In “To filed” enter the requisition number.

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 MRP User Guide and Process Flow

After the enter user will able to see the requsition.

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 MRP User Guide and Process Flow

Requisition Browse
In requisition browse user can show the list of purchase requisitions.

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 MRP User Guide and Process Flow

Action Message Review

Action messages recommend the actions a planner takes to balance supply with
demand, such as rescheduling, canceling, or releasing orders. MRP generates action
messages, as required, for all items with non-blank order policies. Order policy codes
that the system does not recognize are planned as LFL (lot for lot).

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 MRP User Guide and Process Flow

Common Action Messages

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